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Process and Product Monitoring in the Drilling of Critical Aero Engine Components

Apprimus Verlag,
Buch
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Kurzbeschreibung

Major objective of this thesis was the attempt to find an answer to the question, if under
specified boundary conditions signals generated with state of the art monitoring solutions
allow an interpretation of the generated part quality during the manufacture of critical
aero engine components. It is shown in the state of the art of this thesis, that process monitoring
systems are widely used in modern production systems. Their major focus is set
onto cutting and machine tool condition monitoring solutions. Various sensor solutions
are on the market to monitor manufacturing and production system, but up to now no
direct link to the parts quality with the aid of sensor and monitoring systems has been
made. Following the need that sensor and monitoring solutions have to be implemented
into a rather rough production environment, it is asked, how these environmental issues
are influencing the robustness and reliability of the process monitoring system. This question
is discussed in this work, where first non-machining related key process variables are
defined and analyzed. Following this, the question is raised if major machining characteristics
of a drilling process can be monitored and interpreted in such a way, that a correlation
to the machined components quality is possible. To answer this, pure machining
related anomalies and their influence on sensor signals are discussed. This is undertaken
on drilling processes for the two relevant alloys of this thesis, TiAl6V4 and Inconel 718.
A broad range of process characteristics and abnormal behavior during a drilling process
is identified and described with corresponding sensor signals. A possible evaluation for
the creation of signal features is given as an example. Furthermore, an attempt is made
to create a correlation of sensor signals to the life of components. As component life is
usually evaluated by the use of LCF experiments, this has also been carried out within the
thesis work. Various typical anomalies were machined into test blocks, monitored and LCF
tested. A monitoring strategy based on this evaluation is also presented. As it was found
that temperature evolution within the drilling process is critical a new temperature measurement
method has been developed and based on these measurements a temperature
model has been derived from the results for drilling the titanium alloy TiAl6V4.

Details
Schlagworte
Hauptbeschreibung

Titel: Process and Product Monitoring in the Drilling of Critical Aero Engine Components
Autoren/Herausgeber: Drazen Veselovac

ISBN/EAN: 9783863591120

Seitenzahl: 145
Format: 21 x 14,8 cm
Produktform: Taschenbuch/Softcover
Gewicht: 280 g
Sprache: Englisch

Major objective of this thesis was the attempt to find an answer to the question, if under
specified boundary conditions signals generated with state of the art monitoring solutions
allow an interpretation of the generated part quality during the manufacture of critical
aero engine components. It is shown in the state of the art of this thesis, that process monitoring
systems are widely used in modern production systems. Their major focus is set
onto cutting and machine tool condition monitoring solutions. Various sensor solutions
are on the market to monitor manufacturing and production system, but up to now no
direct link to the parts quality with the aid of sensor and monitoring systems has been
made. Following the need that sensor and monitoring solutions have to be implemented
into a rather rough production environment, it is asked, how these environmental issues
are influencing the robustness and reliability of the process monitoring system. This question
is discussed in this work, where first non-machining related key process variables are
defined and analyzed. Following this, the question is raised if major machining characteristics
of a drilling process can be monitored and interpreted in such a way, that a correlation
to the machined components quality is possible. To answer this, pure machining
related anomalies and their influence on sensor signals are discussed. This is undertaken
on drilling processes for the two relevant alloys of this thesis, TiAl6V4 and Inconel 718.
A broad range of process characteristics and abnormal behavior during a drilling process
is identified and described with corresponding sensor signals. A possible evaluation for
the creation of signal features is given as an example. Furthermore, an attempt is made
to create a correlation of sensor signals to the life of components. As component life is
usually evaluated by the use of LCF experiments, this has also been carried out within the
thesis work. Various typical anomalies were machined into test blocks, monitored and LCF
tested. A monitoring strategy based on this evaluation is also presented. As it was found
that temperature evolution within the drilling process is critical a new temperature measurement
method has been developed and based on these measurements a temperature
model has been derived from the results for drilling the titanium alloy TiAl6V4.

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